All Composite Data Products: National FCEV …All Composite Data Products: National FCEV Learning...

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency & Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

Contract No. DE-AC36-08GO28308

Technical Report NREL/TP-5600-53152 November 2011

All Composite Data Products: National FCEV Learning Demonstration With Updates Through October 5, 2011 Keith Wipke, Sam Sprik, Jennifer Kurtz, Todd Ramsden, Chris Ainscough, and Genevieve Saur

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All Composite Data Products: National FCEV Learning Demonstration

With Updates Through

October 5, 2011

Keith Wipke, Sam Sprik,

Jennifer Kurtz, Todd

Ramsden, Chris

Ainscough, Genevieve

Saur

NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

CDP#1: Hours Accumulated and

Projected Hours to 10% Stack Voltage Degradation

Gen1 Gen2 Gen1 Gen2 Gen1 Gen20

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

2006 Target

2009 Target

Actual Operating Hours Accumulated To-Date Projected Hours to 10% Voltage Degradation

Tim

e (

Ho

urs

)

DOE Learning Demonstration Fuel Cell Stack Durability:Based on Data Through 2009 Q2

Max Hrs Accumulated1,2

Avg Hrs Accumulated1,3

Projection to 10% Voltage Degradation4,5,6

Max Projection

Avg Projection

NREL CDP01

Created: Mar-23-10 10:39 AM

(1) Range bars created using one data point for each OEM. Some stacks have accumulated hours beyond 10% voltage degradation.(2) Range (highest and lowest) of the maximum operating hours accumulated to-date of any OEM's individual stack in "real-world" operation.(3) Range (highest and lowest) of the average operating hours accumulated to-date of all stacks in each OEM's fleet.(4) Projection using on-road data -- degradation calculated at high stack current. This criterion is used for assessing progress against DOE targets, may differ from OEM's end-of-life criterion, and does not address "catastrophic" failure modes, such as membrane failure.(5) Using one nominal projection per OEM: "Max Projection" = highest nominal projection, "Avg Projection" = average nominal projection. The shaded projection bars represents an engineering judgment of the uncertainty on the "Avg Projection" due to data and methodology limitations. Projections will change as additional data are accumulated.(6) Projection method was modified beginning with 2009 Q2 data, includes an upper projection limit based on demonstrated op hours.

National Renewable Energy Laboratory 2 Innovation for Our Energy Future

CDP#2: Vehicle Range

Dyno Range (2) Window-Sticker Range (3) On-Road Range (4)(5)0

50

100

150

200

250

300

Veh

icle

Ran

ge (

miles)

Vehicle Range1

2015 Target

2009 Target

Gen 1

Gen 2

NREL CDP02

Created: Mar-10-10 1:18 PM

(1) Range is based on fuel economy and usable hydrogen on-board the vehicle. One data point for each make/model.(2) Fuel economy from unadjusted combined City/Hwy per DRAFT SAE J2572.(3) Fuel economy from EPA Adjusted combined City/Hwy (0.78 x Hwy, 0.9 x City).(4) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(5) Fuel economy calculated from on-road fuel cell stack current or mass flow readings.


CDP#3: Fuel Cell System Power Density,

Including Hydrogen Storage

0

50

100

150

200

250

300

350

400

Po

wer

Den

sit

y (

W/L

)

FC System (Including Hydrogen Storage) Power Density (W/L)

2010 and 2015 FreedomCAR Research Goal1

Gen 1

Gen 2

NREL CDP03NREL CDP03NREL CDP03NREL CDP03

Created: Sep-08-09 10:32 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.


CDP#4: Fuel Cell System Specific Power,

Including Hydrogen Storage

0

50

100

150

200

250

300

350

400

Sp

ecif

ic P

ow

er

(W/k

g)

FC System (Including Hydrogen Storage) Specific Power (W/kg)

2010 and 2015 FreedomCAR Research Goal1

Gen 1

Gen 2

NREL CDP04NREL CDP04

Created: Aug-28-09 8:42 AM (1) Fuel cell system includes fuel cell stack, BOP and H2 storage, but excludes power electronics, battery storage, and electric drive.


CDP#5: Fuel Cell Start Times from

Sub-Freezing Soak Conditions

12 hr Equilibrium 12 hr Equilibrium0

100

200

300

400

500

600

Time to Drive Away Time to Max FC Power

Tim

e [

s]

Fuel Cell Vehicle Start Time from Sub-Freezing Soak Condition1


Created: Sep-08-09 10:54 AM

(1) Learning Demo soak temperature for freeze tests were between -9 and -20 oC

(2) 2010 & 2015 DOE MYPP Cold Start Up Time Target: 30 seconds to 50% of rated power from -20 oC (soak duration not specified).


CDP#6: Fuel Economy

Dyno (1) Window-Sticker (2) On-Road (3)(4)0

10

20

30

40

50

60

70

80

Fu

el E

co

no

my (

miles/k

g H

2)

Fuel Economy

Gen 1

Gen 2

NREL CDP06


(1) One data point for each make/model. Combined City/Hwy fuel economy per DRAFT SAE J2572.(2) Adjusted combined City/Hwy fuel economy (0.78 x Hwy, 0.9 x City).(3) Excludes trips < 1 mile. One data point for on-road fleet average of each make/model.(4) Calculated from on-road fuel cell stack current or mass flow readings.


CDP#7: Fuel Cell Voltage

0

5

10

15

20

25

Op

era

tin

g T

ime [

%]

Operating Time at Fuel Cell Stack Voltage Levels: DOE Fleet

<50%

50-55%

55-60%

60-65%

65-70%

70-75%

75-80%

80-85%

85-90%

90-95%

95-100%>100%

% Max Fuel Cell Stack Voltage

All time

Time at low current

NREL CDP07



CDP#8: FC System Efficiency

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

Net System Power [%]

Eff

icie

ncy [

%]

Fuel Cell System1 Efficiency

2

Eff. at 25% Pwr Eff. at 100% Pwr ------------------- -------------------Gen1 51 - 58% 30 - 54%Gen2 53 - 59% 42 - 53%

DOE Target at 25% Power

DOE Target at 100% Power

Gen 1 Efficiency Range

Gen 2 Efficiency Range



1 Gross stack power minus fuel cell system auxiliaries, per DRAFT SAE J2615. Excludes power electronics and electric drive.

2 Ratio of DC output energy to the lower heating value of the input fuel (hydrogen).

3 Individual test data linearly interpolated at 5,10,15,25,50,75,and 100% of max net power. Values at high power linearly extrapolated

due to steady state dynamometer cooling limitations.


CDP#9: Safety Reports – Vehicles

0

1

2

3

Nu

mb

er

of

Re

po

rts

Safety Reports - Vehicle Operation

Tank Scratch

Traffic Accident

H2 Leak - During Fueling

H2 Alarm - Fuel System

H2 Alarm - Passenger Compartment

Created: Aug-15-11 1:56 PM

NREL cdp_fcev_09


NREL cdp_fcev_09


CDP#10: Storage Weight % Hydrogen

350bar 700bar0

1

2

3

4

5

6

7

8

9

Weig

ht

Perc

en

t H

yd

rog

en

(%

)

Weight Percent Hydrogen

2015 DOE MYPP Target1




Created: Aug-19-08 11:39 AM

1Targets are set for advanced materials-based hydrogen storage technologies.


CDP#11: Volumetric Capacity of H2 Storage

350bar 700bar0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

Mass H

2 p

er

Lit

er

(kg

/L)

Mass of Hydrogen Per Liter






1Targets are set for advanced materials-based hydrogen storage technologies.


CDP#12: Vehicle Hydrogen Tank Cycle Life

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

Nu

mb

er

of

cycle

s

Hydrogen Tank Cycle Life1

All OEMs




Gen 1

Gen 2



1Data reported reference NGV2, HGV2, or EIHP standards.

2Some near-term targets have been achieved with compressed and liquid tanks. Emphasis is on advanced materials-based technologies.


CDP#13: On-Site Hydrogen Production

Efficiency

On-Site Natural Gas Reforming On-Site Electrolysis0

10

20

30

40

50

60

70

80

2010 MYPP Target

2015 MYPP Target

2012 MYPP Target

2017 MYPP Target

Pro

du

cti

on

Eff

icie

ncy (

LH

V %

)

Hydrogen Production Conversion Efficiency1

Average Station Efficiency

Quarterly Efficiency Data

Highest Quarterly Efficiency

Efficiency Probability Distribution2

NREL CDP13


1Production conversion efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis) divided by the sum of

the energy into the production process from the feedstock and all other energy as needed. Conversion efficiency does not includeenergy used for compression, storage, and dispensing.2The efficiency probability distribution represents the range and likelihood of hydrogen production conversion efficiency based on

monthly conversion efficiency data from the Learning Demonstration.


CDP#14: Fueling Rates – 350 and 700 bar

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

500

1000

1500

2000

2500

Avg Fuel Rate (kg/min)

Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling Rates350 vs 700 bar Fills - All Light Duty Through 2009Q4

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 Count------------- ------------------ ------- --------350 bar 0.82 29% 19659700 bar 0.63 4% 5590

350 bar

700 bar

2006 MYPP Tech Val Milestone


NREL CDP14



CDP#15: H2 Production Cost vs. Process

0

2

4

6

8

10

12

14

16

Projected Early Market 1500 kg/day Hydrogen Cost1

$/k

g

Natural Gas Reforming2

Electrolysis2

2015 DOE Hydrogen Program Goal Range3

Median

25th & 75th Percentile

10th & 90th Percentile

Created: Jan-19-10 11:08 AM

(1) Reported hydrogen costs are based on estimates of key cost elements from Learning Demonstration energy company partners and represent thecost of producing hydrogen on-site at the fueling station, using either natural gas reformation or water electrolysis, dispensed to the vehicle. Costsreflect an assessment of hydrogen production technologies, not an assessment of hydrogen market demand.(2) Hydrogen production costs for 1500 kg/day stations developed using DOE’s H2A Production model, version 2.1. Cost modeling represents thelifetime cost of producing hydrogen at fueling stations installed during an early market rollout of hydrogen infrastructure and are not reflective of thecosts that might be seen in a fully mature market for hydrogen installations. Modeling uses default H2A Production model inputs supplemented withfeedback from Learning Demonstration energy company partners, based on their experience operating on-site hydrogen production stations. H2A-based Monte Carlo simulations (2,000 trials) were completed for both natural gas reforming and electrolysis stations using default H2A values and10th percentile to 90th percentile estimated ranges for key cost parameters as shown in the table. Capacity utilization range is based on the capabilitiesof the production technologies and could be significantly lower if there is inadequate demand for hydrogen.(3) DOE has a hydrogen cost goal of $2-$3/kg for future (2015) 1500 kg/day hydrogen production stations installed at a rate of 500 stations per year.

Key H2 Cost Elements and Ranges

Input Parameter Minimum

(P10) Maximum

(P90)

Facility Direct Capital Cost $10M $25M

Facility Capacity Utilization 85% 95%

Annual Maintenance & Repairs $150K $600K

Annual Other O&M $100K $200K

Annual Facility Land Rent $50K $200K

Natural Gas Prod. Efficiency (LHV) 65% 75%

Electrolysis Prod. Efficiency (LHV) 35% 62%

NREL CDP15


CDP#16: Fuel Cell Stack Trips Per Hour

Histogram

0-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >80

5

10

15

20

25

30Segmented Trips/Hour Histogram: DOE Fleet

Trips/Hour*

Fre

qu

en

cy [

%]

*Trips/Hour based on 50 hour segments

spanning stack operating period

NREL CDP16



CDP#17: Statistics of Trips/Hour vs.

Operating Hour

0

1

2

3

4

5

6

7

8

9

10

0-250 250-500 500-750 750-1000 1000-1250 1250-1500 1500-1750 1750-2000Stack Op Hour Groups

Tri

ps/H

ou

r*

Statistics of Trips/Hour vs Operating Hour: DOE Fleet

*Trips/Hour based on 50 hour segments

spanning stack operating period

Data Range

25th & 75th Percentiles

Group Median

Outlier

NREL CDP17



CDP#18: Refueling Rates

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

200

400

600

800

1000

1200

1400

1600

1800


Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling RatesVehicle and Infrastructure

5 kg in

5 minutes

5 kg in

3 minutes

25464 EventsAverage = 0.77 kg/min

23% >1 kg/min

6,219 Events

Average = 0.65 kg/min

5% >1 kg/min



Through 2009Q4

After 2009Q4

NREL cdp_fcev_18



CDP#19: Time Between Trips & Ambient

Temperature

0-10 10-30 30-60 60-360 >3600

5

10

15

20

25

30

35

Time [min]

Tri

p F

req

uen

cy [

%]

Time Between Trips with Ambient Temperature: DOE Fleet

<0oC

0-10oC

10-24oC

24-40oC

>40oC

NREL CDP19



CDP#20: Safety Reports – Infrastructure

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Severi

ty

Total Infrastructure Safety Reports by Severityand Report Type Through 2009 Q4

Alarms Only

Automatic System Shutdown

Electrical Issue

Equipment Malfunction

False Alarm/Mischief

H2 Release - Minor, NO Ignition

H2 Release - Significant, NO Ignition

Manual System Shutdown

Non-H2 Release

Site Power Outage

Structural Issue

System Trouble, not Alarm

NREL CDP20


An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame


CDP#21: Range of Ambient Temperature

During Vehicle Operation

0 2 4 6 8 10 12-30

-20

-10

0

10

20

30

40

50

60

1.4 % trips below 0 oC

Max Op = 140.0 oF

Min Op = -5.8 oF

28.2 % trips above 28 oC

Trip Frequency [%]

Tem

pera

ture

[oC

]

Average Ambient Trip Temperature: DOE Fleet

NREL CDP21



CDP#22: Vehicle Operating Hours

0

5

10

15

20

25

30

35

Nu

mb

er o

f V

eh

icle

s

Total Vehicle Hours

Vehicle Hours: All OEMs, Gen 1 and Gen 2

In Service

Retired (1)

146,584Total Vehicle Hours =

Through 2011 Q2


(1) Retired vehicles have left DOE fleet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009

NREL cdp_fcev_22


CDP#23: Vehicles vs. Miles Traveled

0

5

10

15

20

25

30

35

40

Nu

mb

er

of

Ve

hic

les

Total Vehicle Miles

Vehicle Miles: All OEMs, Gen 1 and 2

In Service

Retired (1)

Total Vehicle Miles Traveled = 3,394,302

Through 2011 Q2


NREL cdp_fcev_23 (1) Retired vehicles have lef t DOE f leet and are no longer providing data to NRELSome project teams concluded in Fall/Winter 2009


CDP#24: Cumulative Vehicle Miles Traveled

3,394,302

-250,000 500,000 750,000

1,000,000 1,250,000 1,500,000 1,750,000 2,000,000 2,250,000 2,500,000 2,750,000 3,000,000 3,250,000 3,500,000 3,750,000

Ve

hic

le M

ile

s T

rav

ele

d

Cumulative Vehicle Miles: All OEMs, Gen 1 and Gen 2


Through 2011 Q2

NREL cdp_fcev_24


CDP#25: Vehicle H2 Storage Technologies

4

83

45

38

-

20

40

60

80

100

120

140

160

180

Cu

mu

lati

ve V

eh

icle

s D

ep

loyed

/Reti

red

1

Vehicle Deployment by On-Board Hydrogen Storage Type

700 bar on-road

350 bar on-road

Liquid H2 on-road

700 bar retired

350 bar retired

Liquid H2 retired

(1) Retired vehicles have left DOE fleet and are no longer providing data to NREL(2) Two project teams concluded in Fall/Winter 2009Created Aug-25-11 9:32 AM

170

NREL cdp_fcev_25

(2)


CDP#26: Cumulative H2 Produced or Dispensed

0

20

40

60

80

100

120

140

160

Mass o

f H

yd

rog

en

(1

000 k

g)

Calendar Quarter

Cumulative Hydrogen Produced or Dispensed Through 2011 Q2

NREL cdp_fcev_26

Created Sep-7-11 11:15 AM

*

*Some project teams concluded in Fall/Winter 2009

147,500 kg of hydrogen produced or dispensed since project inception


CDP#27: Hydrogen Quality Index

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.99.7

99.75

99.8

99.85

99.9

99.95

100

Calc

ula

ted

H2 In

dex (

%)

H2 Calculated Quality Index by Year and Production Method

On-Site NG Reformer (Data Range)

On-Site Electrolysis (Data Range)

Delivered (Data Range)

SAE J2719 APR2008 Guideline

Calculated Data

NREL CDP27


Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4

Year 1 Year 2 Year 3 Year 4 Year 5


CDP#28: Hydrogen Fuel Constituents

0 2 4 6 8 10 12 14 16 18 20

Particulates

g/L

H2 Fuel Constituents

Data Range SAE J2719 APR2008 Guideline Measured Less Than or Equal To (Detection Limited)

0 500 1000 1500 2000 2500 3000

(N2+He+Ar)

He

(Ar+N2)

0 5 10 15 20 25 30 35 40

H2O

Total HC

O2

CO2

CO

NH3

mol/mol (ppm)

0 10 20 30 40 50 60 70 80

Total S*

nmol/mol (ppb)NREL CDP28

Created: Mar-10-10 11:05 AM Data is from Learning Demonstration and California Fuel Cell Partnership testing*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).


CDP#28 Supplemental: Hydrogen

Constituents by Year and Production Method

Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del. Ref. Elec. Del.0

1

2

3

4

5

6

NH

3 (

mo

l/m

ol)

(pp

m)

NH3 (mol/mol)(ppm)Non-H

2 Constituents by Year and Production Method





Measured

Less Than or Equal To (Detection Limited)

NREL CDP28





50

100

150

200

Ar

(m

ol/m

ol)

(pp

m)

Ar (mol/mol)(ppm)Non-H






Measured


NREL CDP28





500

1000

1500

2000

2500

Ar+

N2 (

mo

l/m

ol)

(pp

m)

Ar+N2 (mol/mol)(ppm)

Non-H2 Constituents by Year and Production Method





Measured


NREL CDP28





500

1000

1500

2000

2500

3000

Calc

ult

ate

d T

ota

l C

on

sti

tuen

ts (

mo

l/m

ol)

(pp

m)

Calcultated Total Constituents (mol/mol)(ppm)Non-H






Calculated Data

NREL CDP28





1

2

3

4

5

6

7

8

9

CO

2 (

mo

l/m

ol)

(pp

m)

CO2 (mol/mol)(ppm)






Measured


NREL CDP28





0.2

0.4

0.6

0.8

1

CO

(

mo

l/m

ol)

(pp

m)

CO (mol/mol)(ppm)Non-H






Measured


NREL CDP28





0.02

0.04

0.06

0.08

0.1

Fo

rmald

eh

yd

e (

mo

l/m

ol)

(pp

m)

Formaldehyde (mol/mol)(ppm)Non-H






Measured


NREL CDP28





0.05

0.1

0.15

0.2

Fo

rmic

acid

(

mo

l/m

ol)

(pp

m)

Formic acid (mol/mol)(ppm)Non-H






Measured


NREL CDP28





5

10

15

H2O

(

mo

l/m

ol)

(pp

m)

H2O (mol/mol)(ppm)Non-H






Measured


NREL CDP28





50

100

150

200

250

300

He (

mo

l/m

ol)

(pp

m)

He (mol/mol)(ppm)Non-H






Measured


NREL CDP28





5000

10000

15000

20000

25000

30000

Part

icu

late

Siz

e (

m)

Particulate Size (m)Non-H






Measured


NREL CDP28





500

1000

1500

2000

2500

3000

N2+

He+

Ar

(m

ol/m

ol)

(pp

m)

N2+He+Ar (mol/mol)(ppm)






Measured


NREL CDP28





500

1000

1500

2000

2500

N2 (

mo

l/m

ol)

(pp

m)

N2 (mol/mol)(ppm)






Measured


NREL CDP28





5

10

15

20

25

30

35

40

O2(

mo

l/m

ol)

(pp

m)

O2(mol/mol)(ppm)






Measured


NREL CDP28





2

4

6

8

10

12

14

16

18

20

22

Part

icu

late

Co

ncen

trati

on

(

g/L

)

Particulate Concentration (g/L)Non-H






Measured


NREL CDP28





5

10

15

20

25

To

tal H

alo

gen

ate

s (

mo

l/m

ol)

(pp

m)

Total Halogenates (mol/mol)(ppm)Non-H






Measured


NREL CDP28





0.5

1

1.5

2

To

tal H

C (

mo

l/m

ol)

(pp

m)

Total HC (mol/mol)(ppm)Non-H






Measured


NREL CDP28




(This slide contains 18 graphs (1 for each constituent): view in slide-show mode)


10

20

30

40

50

60

70

To

tal S

* (n

mo

l/m

ol)

(pp

b)

Total S* (nmol/mol)(ppb)Non-H






Measured


NREL CDP28


Data is from Learning Demonstration and California Fuel Cell Partnership testingYear 1 is 2005Q3-2006Q2, Year 2 is 2006Q3-2007Q2, Year 3 is 2007Q3-2008Q2, Year 4 is 2008Q3-2009Q2, and Year 5 is 2009Q3-2009Q4*Total S calculated from SO2, COS, H2S, CS2, and Methyl Mercaptan (CH3SH).



CDP#29: Fueling Rates Communication and

Non-Communication Fills

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

500

1000

1500

2000

2500


Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling RatesComm vs Non-Comm Fills - All Light Duty Through 2009Q4

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Fill Type Avg (kg/min) %>1 ------------- ------------------ -------Comm 0.86 30%Non-Comm 0.66 12%

Comm

Non-Comm



NREL CDP29



CDP#30: Infrastructure Maintenance

0 20 40 60 80 100 120 140 160 180 200

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Labor Hours Per Station Since InceptionThrough 2009 Q4

Scheduled

Un-Scheduled

0 5 10 15 20 25 30 35 40

Adjustment

Check Only

Other

Repair

Replacement

Maintenance: Average Number of Events Per Station Since Inception

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

# of Events

Hours

Comparison of Scheduled/Un-Scheduled Maintenance

NREL CDP30



CDP#31: Number of Online Stations

7

12

6

0

5

10

15

20

25

Nu

mb

er

of

Sta

tio

ns

Reporting Period

Cumulative Stations

Continuing Outside of Project

Retired Stations

Current Project Stations

NREL cdp_fcev_31

Created Aug-15-11 2:52 PM


CDP#32: Infrastructure Hydrogen Production

Methods

0

1

2

3

4

5

6

7

8

9

Compressed Liquid Pipeline Reforming Electrolysis

Nu

mb

er

of

Sta

tio

ns

Learning Demonstration Hydrogen Stations by Type

Operating Outside of Project

Operating Within Project

Historical 2005-2009*

NREL cdp_fcev_32

Created Sep-6-11 3:02 PM

Delivered On-Site Production

*Some project teams concluded Fall/Winter 2009. Markers show the cumulative stations operated during the 2005-2009 period


CDP#33: Percentage of Theoretical Range

Traveled Between Refuelings

0 10 20 30 40 50 60 70 80 90 1000

1

2

3

4

5

6

7

8

9

10

11

12

13Range Histogram: All OEMs

Percentage of chassis dyno range1 between refuelings

Perc

en

tag

e o

f R

efu

elin

gs

0 10 20 30 40 50 60 70 80 90 1000

25

50

75

100

Cu

mu

lati

ve P

erc

en

tag

e

NREL CDP33


Total refuelings2 = 25811

1. Range calculated using the combined City/Hwy fuel economy from dyno testing (not EPAadjusted) and usable fuel on board.2. Some refueling events are not detected/reported due to data noise or incompleteness.


CDP#34: Effective Vehicle Range

0 10 20 30 40 50 60 70 80 90 100

Gen1

Gen2

Vehicle Range Factors

Percentage of chassis dyno range1.

All O

EM

s Win

do

w-S

ticker

2

Win

do

w-S

ticker

2

On

-Ro

ad

3

On

-Ro

ad

3

Dyn

o 1

NREL CDP34


1. Calculated using the combined City/Hwy fuel economy from dyno testing (non-adjusted)and usable fuel on board.2. Applying window-sticker correction factors for fuel economy: 0.78 x Hwy and 0.9 x City.

3. Using fuel economy from on-road data (excluding trips < 1 mile, consistent with other data products).


CDP#35: Average Refuelings Between

Infrastructure Safety Reports

0

2

4

6

8

10

12

14

16

18

20

22

24

Nu

mb

er

of

Sta

tio

ns

Infrastructure Safety Trend and Number of Stations Through 2009 Q4

05Q2

05Q3

05Q4

06Q1

06Q2

06Q3

06Q4

07Q1

07Q2

07Q3

07Q4

08Q1

08Q2

08Q3

08Q4

09Q1

09Q2

09Q3

09Q4

Number of Stations

Avg Refuelings Between Safety Reports

0

100

200

300

400

500

600

Avg

# o

f R

efu

elin

gs B

etw

een

Safe

ty R

ep

ort

s

7 1132 34

88102

115

4768

124101

57 5473

51

138

447

121

198

NREL CDP35

Created: Mar-23-10 2:43 PM Reporting Period


CDP#36: Type of Infrastructure Safety Report

By Quarter

0

10

20

30

40

50

Nu

mb

er

of

Rep

ort

s

Type of Infrastructure Safety Reports by Quarter Through 2011 Q2

05Q2

05Q3

05Q4

06Q1

06Q2

06Q3

06Q4

07Q1

07Q2

07Q3

07Q4

08Q1

08Q2

08Q3

08Q4

09Q1

09Q2

09Q3

09Q4

10Q1

10Q2

10Q3

10Q4

11Q1

11Q2

Incident

Near Miss

Non-Event

Avg # Reports/Station

NREL cdp_fcev_36


Reporting PeriodAn INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame


CDP#37: Primary Factors of Infrastructure

Safety Reports

0 50 100 150 200 250 300

Non-Event

Near Miss

Incident

Number of Reports

Severi

ty

Primary Factors of Infrastructure Safety ReportsThrough 2009 Q4

Calibration/Settings/ Software Controls

Design Flaw

Electrical Power to Site

Environment (Weather, Power Disruption, Other)

False Alarm

Inadequate Training, Protocol, SOP

Inadequate/ Non-working Equipment

Maintenance Required

Mischief, Vandalism, Sabotage

New Equipment Materials

Not Yet Determined

Operator/Personnel Error

System Manually Shutdown

NREL CDP37


An INCIDENT is an event that results in: - a lost time accident and/or injury to personnel - damage/unplanned downtime for project equipment, facilities or property - impact to the public or environment - any hydrogen release that unintentionally ignites or is sufficient to sustain a flame if ignited - release of any volatile, hydrogen containing compound (other than the hydrocarbons used as common fuels)A NEAR-MISS is: - an event that under slightly different circumstances could have become an incident - unplanned H2 release insufficient to sustain a flame


CDP#38: Refueling Times

0 1 2 3 4 5 6 7 8 9 100

500

1000

1500

2000

2500

3000

3500

Time (min)

Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling TimesVehicle and Infrastructure

Average = 3.26 min86% <5 min

Average = 4.47 min

70% <5 min

2006 MYPP Tech Val Milestone (5 kg in 5 min)

2012 MYPP Tech Val Milestone (5 kg in 3 min)

Through 2009Q4

After 2009Q4

NREL cdp_fcev_38



CDP#39: Refueling Amounts

0 1 2 3 4 5 6 70

100

200

300

400

500

600

700

800

900

1000

Amount Fueled (kg)

Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling AmountsVehicle and Infrastructure

Average = 2.13 kg

Average = 2.67 kg

Through 2009Q4

After 2009Q4

NREL cdp_fcev_39



CDP#40: H2 Tank Level at Refueling

Through 2009Q4

After 2009Q4

Tank Levels: DOE Fleet

14%

FE

14%

NREL cdp_fcev_40

1. Some refueling events not recorded/detected due to data noise or incompleteness.

2. The outer arc is set at 20% total refuelings.

3. If tank level at fill was not available, a complete fill up was assumed.

Median Tank Level (At Fill) = 42% Total refuelings1 = 27113


Total refuelings1 = 9034Median Tank Level (At Fill) = 50%


CDP#41: Refueling Tank Levels - Medians

FE

Tank Level Medians (At Fill): DOE Fleet, All Vehicles

NREL CDP41


Total refuelings1 = 27113

1. Some refueling events not recorded/detected due to data noise or incompleteness.

2. If tank level at fill was not available, a complete fill up was assumed.


CDP#42: Refueling by Time of Day

Through 2009Q4

After 2009Q4

Refueling by Time of Day

9%

3

12

9

6

Total Fill3 Events = 22657% of fills b/t 6 AM & 6 PM: 89.7%

1. Fills between 6 AM & 6 PM

2. The outer arc is set at 12 % total Fill.

3. Some events not recorded/detected due to data noise or incompleteness.

AM PM

10%

NREL cdp_fcev_42


Total Fill3 Events = 9054% of fills b/t 6 AM & 6 PM: 88.5%


CDP#43: Refueling by Day of Week

Sun Mon Tues Wed Thur Fri Sat0

5

10

15

20

25Refueling by Day of Week

% o

f F

ills

in

a D

ay

Day

Through 2009Q4

After 2009Q4

NREL cdp_fcev_43



CDP#44: Driving Start Time – Day

Driving by Time of Day

9%

3

12

9

6

Total Driving3 Events = 295222% of driving trips b/t 6 AM & 6 PM: 85.3%

1. Driving trips between 6 AM & 6 PM

2. The outer arc is set at 12 % total Driving.


AM PM

7%

% of NHTS trips b/t 6 AM & 6 PM: 81.5%

Through 2009Q4

After 2009Q4

NHTS

NREL cdp_fcev_44


Total Drive3 Events = 36839% of driving trips b/t 6 AM & 6 PM: 74.5%

2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001


CDP#45: Driving by Day of Week


5

10

15

20

25Driving by Day of Week

% o

f T

rip

s in

a D

ay

Day

Through 2009Q4

After 2009Q4

NHTS

NREL cdp_fcev_45


2001 NHTS Data Includes Car, Truck, Van, & SUV day tripsASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001


CDP#46: Fuel Cell System Operating Power

0

10

20

30

40

50

Time at Fuel Cell Stack Power Levels: DOE Fleet

Op

era

tin

g T

ime [

%]

0-5%

5-10

%

10-1

5%

15-2

0%

20-2

5%

25-3

0%

30-3

5%

35-4

0%

40-4

5%

45-5

0%

50-5

5%

55-6

0%

60-6

5%

65-7

0%

70-7

5%

75-8

0%

80-8

5%

85-9

0%

90-9

5%

95-1

00%

>100

%

% Max Fuel Cell Power (Gross)

All time

Time with 0 speed

NREL CDP46



CDP#47: Trip Length

0 5 10 15 20 250

5

10

15

20

25

30

35

40

45

Tri

p F

req

uen

cy [

%]

Trip Length [miles]

Trip Length: DOE Fleet

DOE Fleet

NHTS

NREL CDP47




CDP#48: Primary Factors Affecting Learning

Demo Fleet Fuel Cell Degradation

DOE Fleet

High Current Time

Hot Starts

Starts/hour

Low Voltage Time

High Voltage Time

Cold Starts

Short Trips

0 Speed Trips

Hot Ambient Temp

H*

H*

1) On-going fuel cell degradation study using Partial Least Squares (PLS)

regression model for combined Learning Demonstration Fleet.

2) DOE Fleet model has a low percentage of explained decay rate variance.

Created: Feb-21-08 9:32 AM

H*: Factor group associated with high decay rate fuel cell stacks

L**: Factor group associated with low decay rate fuel cell stacks

Due to differences among teams, the

DOE Fleet Analysis results are spread

out and concrete conclusions are difficult

to draw.

Individual team analyses (CDP#49)

focused on patterns within a fleet.

NREL CDP48


CDP#49: Primary Factors Affecting Learning

Demo Team Fuel Cell Degradation


Team 1

High Voltage Time

Low Current Time

Short Trips

Low Speed

Team 2

Team 3

Team 4

Low Current Time

Long Trips

Warm Ambient Temp

Zero Speed

Current Transients

High Voltage Time

Low Current Time

Short Trips

Low Speed

Current Transients

1) On-going fuel cell degradation study using Partial Least Squares (PLS)

regression model for each team’s Gen 1 fleet.

2) Teams’ PLS models have a high percentage of explained decay rate

variance, but the models are not robust and results are scattered.

3) Factor groups associated with stacks that are opposite to the identified

groups here are not specified.

H*

Starts/Hour

Zero Speed

Short Trips

Low Voltage Time

High Current Time

Current Transients

Cold Starts

Hot Ambient Temp

High Speed

H*

H*

H*

H*

H*: Factor group associated with high decay rate fuel cell stacks


NREL CDP49

CDP#50: Refueling by Time of Night

Refueling by Time of Night: DOE Fleet

3%

3

12

9

6

Total Fill3 Events = 22657% of fills b/t 6 PM & 6 AM: 10.3%

1. Fills between 6 PM & 6 AM

2. The outer arc is set at 12 % total Fill.


PM AM

NREL CDP50



CDP#51: Driving Start Time – Night

Driving Start Time - Night: DOE Fleet

4%

3

12

9

6

Total Driving3 Events = 295222% of driving trips b/t 6 PM & 6 AM: 14.7%

1. Driving trips between 6 PM & 6 AM

2. The outer arc is set at 12 % total Driving.


PM AM

% of NHTS trips b/t 6 PM & 6 AM: 18.4%

NREL CDP51

DOE Fleet

NHTS

NREL CDP51


2001 NHTS Data Includes Car, Truck, Van, & SUV day trips ASCII.csv Source: http://nhts.ornl.gov/download.shtml#2001


CDP#52: Refueling Data by Year

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

100

200

300

400

500

600

700


Nu

mb

er

of

Fu

elin

g E

ven

ts

Histogram of Fueling RatesAll Light Duty by Year Through 2009Q4

5 minute fill of

5 kg at 350 bar

3 minute fill of

5 kg at 350 bar

Year Avg (kg/min) %>1 ------- ----------------- -------2005 0.66 16%2006 0.74 21%2007 0.81 26%2008 0.77 23%2009 0.77 22%

2005

2006

2007

2008

2009



NREL CDP52



CDP#53: Fuel Cell System Energy within

Power Levels

0

2

4

6

8

10FC Energy by Power Levels: DOE Fleet

FC

En

erg

y [

%]

0-5%

5-10

%

10-1

5%

15-2

0%

20-2

5%

25-3

0%

30-3

5%

35-4

0%

40-4

5%

45-5

0%

50-5

5%

55-6

0%

60-6

5%

65-7

0%

70-7

5%

75-8

0%

80-8

5%

85-9

0%

90-9

5%

95-1

00%

>100

%

% Fuel Cell Power (Gross) of Max

Cu

mu

lati

ve %

0

20

40

60

80

100

NREL CDP53



CDP#54: Time Between Trips

0-1 hr 1-6 hr 6-12 hr 12-18hr 18-24hr 1-7days 7-30days >30days0

10

20

30

40

50

60

Tri

p F

req

uen

cy [

%]

Time

Time between Trips: DOE Fleet

0-10 min 10-20 min 20-30 min 30-40 min 40-50 min 50-60 min0

10

20

30

40

50

% T

rip

s

Time

0-60 min Breakdown: DOE Fleet

NREL CDP54



CDP#55: Fuel Cell System Energy

<-0.5 -0.5-0 0-0.5 0.5-1 1-1.5 1.5-2 2-2.5 2.5-3 3-3.5 3.5-4 4-4.5 4.5-5 >50

10

20

30

40

50

60

Energy Consumed [kWh]

Tri

p F

req

uen

cy [

%]

Energy in Trip: DOE Fleet

Net batterycharge in trip

Battery

Vehicle Motor

FC

NREL CDP55



CDP#56: Daily Driving Distance

0 5 10 15 20 25 30 35 400

2

4

6

8

10

12

14

16

18

20

Tri

p F

req

uen

cy [

%]

Daily Distance [miles]

Daily Distance: DOE Fleet

DOE Fleet

NHTS

NREL CDP56


Cumulative Frequency@ 20 miles

DOE Fleet: 47.4%NHTS: 27.2%

Cumulative Frequency@ 40 miles

DOE Fleet: 67.2%NHTS: 52.9%



CDP#57: H2 Storage System Mass and Volume

Breakdown

73%

24%

3%

Average Breakout of H2 Storage System Volume

3.26%

73%

23%

Average Breakout of H2 Storage System Mass

56%35%

9%

H2 Volume (%)

Pressure Vessel Volume (%)

Balance of Plant Volume (%)

3.33%

72%

24%

H2 Mass (%)

Pressure Vessel Mass (%)

Balance of Plant Mass (%)Created: Aug-19-08 9:14 AM

350 bar

700 bar

NREL CDP57


CDP#58: Fuel Cell System Power Density

0

100

200

300

400

500

600

700

Po

wer

Den

sit

y (

W/L

)

FC System Power Density (W/L)

2010 and 2015 DOE MYPP Target1

Gen 1

Gen 2


Created: Sep-17-08 10:29 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.


CDP#59: Fuel Cell System Specific Power

0

100

200

300

400

500

600

700

Sp

ecif

ic P

ow

er

(W/k

g)

FC System Specific Power (W/kg)

2010 and 2015 DOE MYPP Target1

Gen 1

Gen 2


Created: Sep-17-08 10:30 AM (1) Fuel cell system includes fuel cell stack and BOP but excludes H2 storage, power electronics, and electric drive.


CDP#60: On-Site Hydrogen Production

Efficiency vs. Capacity Utilization

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

Production Capacity Utilization1 [%]

Pro

du

cti

on

Co

nvers

ion

Eff

icie

ncy

2 [

%]

Monthly Production Conversion Efficiency vs Utilization

Electrolysis Data

Electrolysis Fit3

Electrolysis Fit Confidence

Natural Gas Data

Natural Gas Fit3

Natural Gas Fit Confidence

NREL CDP60


1) 100% production utilization assumes operation 24 hrs a day, 7 days a week2) Production conversion efficiency is defined as the energy of the hydrogen out of the process (on a LHV basis) divided by the sum of the energy into the productionprocess from the feedstock and all other energy as needed. Conversion efficiency does not include energy used for compression, storage, and dispensing.

3) High correlation with electrolysis data (R2 = 0.82) & low correlation with natural gas data (R

2 = 0.060)


CDP#61: Refueling Station Compressor

Efficiency

On-Site Compression Energy0

10

20

30

40

50

60

70

Co

mp

ressio

n E

nerg

y (

MJ/k

g)

On-Site Compression Efficiency0

10

20

30

40

50

60

70

80

90

100

2010 MYPP Compression Target

2015 MYPP Compression Target

Co

mp

ressio

n E

ffic

ien

cy (

%)

On-Site Hydrogen Compression Efficiency1 and Energy Use

Average Station Compression Efficiency

Quarterly Compression Efficiency Data

Highest Quarterly Compression Efficiency

Average Station Compression Energy

Quarterly Compression Energy Data

Lowest Quarterly Compression Energy

NREL CDP61


1Consistent with the MYPP, compression efficiency is defined as the energy of the hydrogen out of the process (on an LHV basis ) divided by the sum of the

energy of the hydrogen output plus all other energy needed for the compression process. Data shown for on-site hydrogen prod uction and storage

facilities only, not delivered hydrogen sites.

Compression Energy Requirement:

On average, 11.3% of the energy

contained in the hydrogen fuel is

required for the compression

process.


CDP#62: Learning Demonstration Vehicle

Greenhouse Gas Emissions

0

100

200

300

400

500

600

700

WT

W G

HG

Em

issio

ns (

g C

O2-e

q/m

i)

Learning Demonstration Fuel Cycle Well-to-Wheels Greenhouse Gas Emissions1

Baseline Conventional Mid-Size Passenger Car2

Baseline Conventional Mid-Size SUV2

Average WTW GHG Emissions (Learning Demo)

Minimum WTW GHG Emissions (Learning Demo)

WTW GHG Emissions (100% Renewable Electricity)

WTW GHG Probability Based on Learning Demo3

NREL CDP62


On-Site Natural Gas Reforming On-Site Electrolysis(4)

1. Well-to-Wheels greenhouse gas emissions based on DOE's GREET model, version 1.8b. Analysis uses default GREET values except for FCV fuel economy, hydrogen

production conversion efficiency, and electricity grid mix. Fuel economy values are the Gen 1 and Gen 2 window-sticker fuel economy data for all teams (as used in CDP #6);

conversion efficiency values are the production efficiency data used in CDP #13.

2. Baseline conventional passenger car and light duty truck GHG emissions are determined by GREET 1.8b, based on the EPA window-sticker fuel economy of a conventional

gasoline mid-size passenger car and mid-size SUV, respectively. The Learning Demonstration fleet includes both passenger cars and SUVs.

3. The Well-to-Wheels GHG probability distribution represents the range and likelihood of GHG emissions resulting from the hydrogen FCV fleet based on window-sticker fuel

economy data and monthly conversion efficiency data from the Learning Demonstration.

4. On-site electrolysis GHG emissions are based on the average mix of electricity production used by the Learning Demonstration production sites, which includes both

grid-based electricity and renewable on-site solar electricity. GHG emissions associated with on-site production of hydrogen from electrolysis are highly dependent on

electricity source. GHG emissions from a 100% renewable electricity mix would be zero, as shown. If electricity were supplied from the U.S. average grid mix, average GHG

emissions would be 1330 g/mile.


CDP#63: Hydrogen Fueling Station

Maintenance by System

13%

13%

18%

22%

By Number of EventsTotal Number of Events = 2491

20%12%

17%

21%

By Labor HoursTotal Hours = 11430

system control & safety

compressor

reformer

electrolyzer

dispenser

other

valves & piping

electrical

storage

NREL CDP63


Hydrogen Fueling Station Maintenance


CDP#64: Fuel Cell Vehicle Maintenance by

System

3%5%

34%

58%

Fuel Cell Vehicle Events (11574)

18%

8%

50%

24%

Fuel Cell Vehicle Labor (12522 hours)

Vehicle (non-powertrain)

Fuel Cell System

Powertrain

Battery

4%10%

12%

13%

23%

39%

Fuel Cell System Events (3916)< 1%

27%

28%11%

11%

22%

Fuel Cell System Labor (6304 hours)

Thermal Management

Air System

Controls, Electronics, Sensors

Fuel System

Fuel Cell Stack

Other

NREL CDP64


Fuel Cell Vehicle Maintenance Events and Labor Hours


CDP#65: Percent Idle in Trip with

Comparison to Standard Drive Cycles

0

2

4

6

8

10

12

14

1015 C

ycle

UD

DS

Cycle

US

06 C

ycle

HW

FE

T C

ycle

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Percent Idle in Trip

% Idle

Tri

p F

req

uen

cy [

%]

NREL CDP65



CDP#66: FCV Speed with Comparison to

Standard Drive Cycles

0 5 10 15 20 25 30 35 40 45 50 55 60 65 700

5

10

15

20

25

30

35

40

Speed [mph]

Op

era

tio

n T

ime [

%]

Fuel Cell Vehicle Speed

DOE Fleet Speed

DOE Fleet Idle

1015 Cycle (14.1 mph avg)

UDDS Cycle (19.6 mph avg)

HWFET Cycle (48.0 mph avg)

US06 Cycle (48.2 mph avg)

NREL CDP66



CDP#67: Fuel Cell Stack Operation Hours

0

5

10

15

20

25

30

35

40

Sta

ck C

ou

nt

Fuel Cell Stack Operation Hours: Gen1

Gen1

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Gen1 Hours

24% of stacks in operation

In Op1

Retired2

Other3

0

5

10

15

20

25

30

35

40

Sta

ck C

ou

nt

Fuel Cell Stack Operation Hours: Gen2

Gen2

0

200

400

600

800

1000

1200

1400

1600

1800

2000

Gen2 Hours

34% of stacks in operation

In Op1

Retired2

Other3

NREL CDP67


1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance. Some project teams concluded in Fall/Winter 2009


CDP#68: Power Drop During Fuel Cell Stack

Operation Period

0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

Sta

ck C

ou

nt

% FC Power Drop

FC Power Drop During Operation Period: Gen1

Gen1

60% of In Op stacks

have > 10% power drop

In Op1

Retired2

Other3

0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

Sta

ck C

ou

nt

% FC Power Drop

FC Power Drop During Operation Period: Gen2

Gen2

85% of In Op stacks

have > 10% power drop

In Op1

Retired2

Other3

NREL CDP68


1) Stack currently accumulating hours2) Stack removed for low performance3) Stack not currently accumulating hours, but not removed because of low performance. Some project teams concluded in Fall/Winter 2009


CDP#69: Max Fuel Cell Power Degradation – Gen 1

30

40

50

60

70

80

90

100

110

120

130

0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)

% P

ow

er(

1)

Max Fuel Cell Power Loss vs Op Hours: Gen1

1) Normalized by fleet median value at 200 hours.

2) Each segment point is median FC power (+-50 hrs).

Box not drawn if fewer than 3 points in segment.

Gen1Data Range


Group Median

Outlier

NREL CDP69



CDP#70: Max Fuel Cell Power Degradation – Gen 2

30

40

50

60

70

80

90

100

110

120

130

0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000Stack Op Hour Segments(2)

% P

ow

er(

1)

Max Fuel Cell Power Loss vs Op Hours: Gen2


2) Each segment point is median FC power (+-50 hrs).

Box not drawn if fewer than 3 points in segment.

Gen2Data Range


Group Median

Outlier

NREL CDP70



CDP#71: Projected Hours to OEM Low Power

Operation Limit

0-200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

5

10

15

20

25

30

27% Gen1 > 2000 projected hrs17% Gen2 > 2000 projected hrs

Projected Hours

% S

tacks

Durability: Projected Hours to Low Fuel Cell Power Limit

Gen1 (> 200 operation hrs)

Gen1 (< 200 operation hrs)

Gen2 (> 200 operation hrs)

Gen2 (< 200 operation hrs)

NREL CDP71


1. Low fuel cell power limit is dependent on the fuel cell vehicle system and is unique to each company in this Learning Demonstration.2. Acceptable low vehicle performance limit will be determined by retail customer expectations.3. Power projection method based on the voltage degradation techniques, but uses max fuel cell power instead of voltage at a specifichigh current.4. Stacks with less than 200 operation hours are in separate groups because the projection is based on operation data and with operationhours greater than 200 the degradation rate tends to flatten out.


CDP#72: Difference Between Tank and

Ambient Temperature Prior to Refueling

-20 0 20 40 60-20

-10

0

10

20

30

40

50

60

Ambient Air Temperature [deg C]

Tan

k T

em

pera

ture

[d

eg

C]

Tank vs. Ambient Air Temps Prior to Refueling

Fre

qu

en

cy

50

100

150

200

250

300

-40 -20 0 20 400

500

1000

1500

2000

Delta Temperature [deg C]

Co

un

t

Delta Temperature: Tank minus Ambient

Delta Temp Histogram

Normal Distribution Fit

0

0.02

0.04

0.06

0.08

Den

sit

y

Mean= -3.751Std Dev= 6.129

NREL CDP72


-This CDP created in support of SAE J2601 related to refueling

-Temperatures are prior to refueling and exclude data within 4 hours of a previous fill

-The plot to the left excludes ambient temperatures less than -5 deg C


CDP#73: Fuel Cell Stack Projected Hours as

a Function of Voltage Drop

10 15 20 25 300

200

400

600

800

1000

1200

1400

1600

1800

2000Fuel Cell Stack Projected Hours as a Function of Voltage Drop

% Voltage Drop

Pro

jecte

d H

ou

rs2,3

Gen 1 Average Projections

Gen 1 Average Projection to 10% Voltage Degradation1

Gen 2 Average Projections

Gen 2 Average Projection to 10% Voltage Degradation1

NREL CDP73


(1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance.(2) Projections using on-road data -- degradation calculated at high stack current.(3) Curves generated using the Learning Demonstration average of each individual fleet average at various voltage degradation levels.(4) The projection curves display the sensitivity to percentage of voltage degradation, but the projections do not imply that all stacks will (or do) operate at these voltage degradation levels.(5) The voltage degradation levels are not an indication of an OEM's end-of-life criteria and do not address catastrophic stack failures such as membrane failure.(6) All OEM Gen 2 average fleet projections are higher than Gen1 projections, however due to less operation data for Gen 2, these projections are limited by demonstrated operation hours to minimize extrapolations.


CDP#74: Fuel Cell Transient Cycle Count per

Mile and per Minute

0 2 4 6 8 10 12 14 16 18 200

5

10

15

20

Cycle Per Mile

Tri

p F

req

ue

nc

y [

%]

Number of Cycles1 per Trip Mile

0 2 4 6 8 10 12 14 16 18 200

10

20

30

40

50

60

Cycle Per Min

Tri

p F

req

ue

nc

y [

%]

Number of Cycles1 per Trip Minute

Gen1 Gen20

10

20

30

40

Cy

cle

pe

r M

ile

Range of Fleet Average Cycle1 per Mile

Gen1 Gen21

2

3

4

5

6

7

Cy

cle

pe

r M

in

Range of Fleet Average Cycle1 per Min

NREL CDP74

Created: Mar-22-10 4:46 PM 1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.


CDP#75: Fuel Cell Transient Voltage and

Time Change


CDP#76: Fuel Cell Transient Rate by Cycle

Category

0

5

10

15

20

25

30

35

Dow

nUp

Slo

wUp

Slo

wDow

n

Slo

wDow

nUp

Dow

nSSUp

Fre

qu

en

cy [

%]

Transient Cycle1 Count by Category2

0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

dV/dtF

req

uen

cy [

%]

DownUp Cycle1 dV/dT

0 5 10 15 20 25 30 35 400

10

20

30

40

50

dV/dt

Fre

qu

en

cy [

%]

SlowUp Cycle1 dV/dT

0 5 10 15 20 25 30 35 400

10

20

30

40

50

dV/dt

Fre

qu

en

cy [

%]

SlowDown Cycle1 dV/dT

0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

dV/dt

Fre

qu

en

cy [

%]

SlowDownUp Cycle1 dV/dT

0 5 10 15 20 25 30 35 400

20

40

60

80

100

dV/dtF

req

uen

cy [

%]

DownSSUp Cycle1 dV/dT

NREL CDP76

Created: Mar-22-10 4:46 PM1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.


CDP#77: Fuel Cell Transient Voltage

Changes by Cycle Category

0

5

10

15

20

25

30

35

Dow

nUp

Slo

wUp

Slo

wDow

n

Slo

wDow

nUp

Dow

nSSUp

Fre

qu

en

cy [

%]

Transient Cycle1 Count by Category2

0

5

10

15

20

-34

-30

-26

-22

-18

-14

-10 -6 -2 2 6

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]F

req

uen

cy [

%]

DownUp Cycle1 dV

0

5

10

15

20

-34

-30

-26

-22

-18

-14

-10 -6 -2 2 6

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]

Fre

qu

en

cy [

%]

SlowUp Cycle1 dV

0

2

4

6

8

10

12

-34

-30

-26

-22

-18

-14

-10 -6 -2 2 6

10

14

18

22

26

30

34


Fre

qu

en

cy [

%]

SlowDown Cycle1 dV

0

2

4

6

8

10

12-3

4-3

0-2

6-2

2-1

8-1

4-1

0 -6 -2 2 61

01

41

82

22

63

03

4


Fre

qu

en

cy [

%]

SlowDownUp Cycle1 dV

0

5

10

15

20

-34

-30

-26

-22

-18

-14

-10 -6 -2 2 6

10

14

18

22

26

30

34

% Voltage Change [%Max Stack Voltage]F

req

uen

cy [

%]

DownSSUp Cycle1 dV

NREL CDP77

Created: Mar-22-10 4:46 PM1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.


CDP#78: Fuel Cell Transient Cycles Outside

of Specified Voltage Levels

0

5

10

15

20

25

30

35

Dow

nUp

Slo

wUp

Slo

wDow

n

Slo

wDow

nUp

Dow

nSSU

p

Cycle

Fre

qu

en

cy [

%]

Transient Cycle Count by Category4

Total

<LoV Level2

>HiV Level3

tV

Example

0 2 4 6 8 10 12 14 16 18 200

10

20

30

40

50

60

70

80

Count per Mile

Tri

p F

req

uen

cy [

%]

Cycles1 Outside of Voltage Levels

2,3

<LoV Level2

>HiV Level3

NREL CDP78


1) A fuel cell voltage transient cycle has a decrease and increase with a minimum delta of 5% max stack voltage.2) The low voltage level is 70% Max Stack Voltage3) The high voltage level is 90% Max Stack Voltage4) Cycle categories based on cycle up and down times. A slow up or down transient has a time change >= 5 seconds. SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.


CDP#79: Percentage of Trip Time at Steady

State

0 5 10 15 20 25 30 35 40 45 500

2

4

6

8

10

12

14

16

18

% Time

Tri

p F

req

uen

cy [

%]

Percent of Trip Time at Steady State

NREL CDP79

Created: Mar-22-10 4:46 PM1) SS = Steady State, where the time change is >= 10 seconds and the voltage change is <= 2.5% max stack voltage.


CDP#80: Miles Between Refuelings

0 50 100 150 200 250 3000

5

10

Perc

en

tag

e o

f R

efu

elin

gs

Distance between refuelings [Miles]2

Distance Driven Between Refuelings: All OEMs

Gen1

Gen2

After 2009Q4

NREL cdp_fcev_80

1. Some refueling events are not detected/reported due to data noise or incompleteness.

2. Distance driven between refuelings is indicative of driver behavior and does not represent the full range of the vehicle.

Gen1

Refuelings1 = 18941

Median distance between refuelings = 56 Miles Gen2

Refuelings1 = 6870

Median distance between refuelings = 81 Miles


Refuelings after 2009Q41 = 8964

Median distance between refuelings = 96 Miles


CDP#81: Average Trip Speed

0 5 10 15 20 25 30 35 40 450

2

4

6

8

10

12

14

16

18

20

Tri

p F

req

uen

cy

1 [

%]

Average Trip Speed [mph]

Histogram of Average Trip Speed

179,424 trips

1) Excludes trips <= 1 mile (40.9%)

29,689 trips

Average trip speed of 25.4 mph

1) Excludes trips <= 1 mile (19.4%)2) 2001 NHTS data includes Car, Truck, Van & SUV day trips

Through 2009Q4

After 2009Q4

NHTS Data2

NHTS Avg Speed

NREL cdp_fcev_81

Average trip speed of 23.2 mph



CDP#82: Daily FC Operation Hours in

Automotive Application

0 1 2 3 40

20

40

60

80

Hours of Operation Per Day

Days o

f O

pera

tio

n [

%]

Fuel Cell System Operation Hours Per Day

Through 2009Q4

After 2009Q4

0 1 2 3 40

20

40

60

80

Average Hours of Operation Per Day

Fu

el C

ell S

yste

ms [

%]

Average Daily Fuel Cell System Operation Hours

9.9% Fuel Cell Systems Average > 30 mins Daily

17.8% Fuel Cell Systems Average > 30 mins Daily

Through 2009Q4

After 2009Q4

NREL cdp_fcev_82



CDP#83: Hydrogen Dispensed by Day of

Week


2

4

6

8

10

12

14

16

18

20

Dis

pen

sed

Hyd

rog

en

[%

of

tota

l]

Day of Week

Dispensed Hydrogen per Day of Week

0

3

6

9

12

15

18

21

24

27

30

Avera

ge k

g

All Stations

Individual Stations

NREL cdp_fcev_83



CDP#84: Effect of Average Trip Speed on

Fuel Economy

0 5 10 15 20 25 30 35 40 45 50 550

0.2

0.4

0.6

0.8

1

1.2Effect of Average Trip Speed on Fuel Economy

1F

uel E

co

no

my [

no

rmalized

]

Avg Trip Speed [miles/hour]

Average of Fleet Medians

25th to 75th Percentile

NREL cdp_fcev_84

Created: Sep-22-11 1:35 PM

(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 mph for calculating median and percentiles.


CDP#85: Effect of Trip Length on Fuel

Economy

0 10 20 30 40 50 60 700

0.2

0.4

0.6

0.8

1

1.2Effect of Average Trip Length on Fuel Economy

1F

uel E

co

no

my [

no

rmalized

]

Trip Length [miles]

Average of Fleet Medians

25th to 75th Percentile

NREL cdp_fcev_85


(1) Data after 2009Q4. The data has been normalized to the max of the median curve for each fleet. Data binned every 5 miles for calculating median and percentiles.


CDP#86: Fuel Cell Stack Operation Hours

0 200 400 600 800 1000 1200 1400 1600 1800 2000 >20000

5

10

15

20

25Fuel Cell Stack

4 Operation Hours

FC

Sta

cks [

%]

Operation Hours

25% of FC Stacks > 920 hours

Med

ian

(677 h

ou

rs)

In Service1

Retired2

Not in Service3

NREL cdp_fcev_86


1) Stacks that are in service and accumulating operation hours.2) Stacks retired due to low-performance or catastrophic failure.3) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performancerelated issues or c)removed from DOE program.4) Only includes systems operating after 2009Q4.


CDP#87: Fuel Cell Stacks Projected Hours to

10% Voltage Degradation with Two Fits

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000

10

20

30

40

50

60Fuel Cell Stacks

4 Projected Hours to 10% Voltage Degradation

1,7

68

FC

Sta

cks [

%]

Time 0 Fit (In Service)

Time 0 Fit (Retired or Not in Service)2

Weighted Average (Fleet)

0 300 600 900 1200 1500 1800 2100 2400 2700 3000 >30000

10

20

30

40

50

60

2,2

12

Projected Hours to 10% Voltage Degradation 1,3

FC

Sta

cks [

%]

Steady Operation Fit (In Service)5

Steady Operation Fit (Retired or Not in Service)2,

5

Weighted Average (Fleet)

NREL cdp_fcev_87


1) Projection using field data, calculated at high stack current, from operation hour 0 or a steady operation period. Projected hours may differ from an OEM's end-of-life criterion and does not address "catastrophic" failure modes.2) Indicates stacks that are no longer accumulating hours either a) temporarily or b) have been retired for non- stack performance related issues or c) removed from DOE program.3) Projected hours limited based on demonstrated hours.4) Only includes systems operating after 2009Q4.5) Not all stacks have a steady operation fit which is calculated from data after 200 hr break-in period. The steady operation starting hour is an approximation of the period after initial break-in where degradation levels to a more steady rate.


CDP#88: Comparison of Fuel Cell Operation Hours

and Projected Hours to 10% Voltage Degradation

0 500 1000 1500 2000

0

500

1000

1500

2000

2500

3000

3500Comparison of Operation Hours and Projected Hours to 10% Voltage Degradation

5

Pro

jecte

d H

ou

rs1,2

,4

Operation Hours

projected hrs = operation hrs

FC System

FC System (Limited)2

FC System (Retired)3

Unity Line

NREL cdp_fcev_88


24% of stacks are

below the unity line

and have operated

past 10% voltage

degradation.

On average, these

stacks have

operated for 1,050

hours.

Stacks above the

unity line have not

operated past 10%

voltage degradation.

1) Indicates the projected hours to a 10% voltage degradation based upon curve fitting data from operation hour 0.2) Projected hours limited based on demonstrated hours.3) Stacks retired due to low-performance or catastrophic failure.4) Each projection has uncertainty based on the confidence intervals of the fit.5) Only includes systems operated after 2009Q4.


CDP#89: Fuel Cell Stack Durability as a

Function of Voltage Drop

10 15 20 25 300

500

1000

1500

2000

2500

3000

3500

4000Fuel Cell Stack

6 Durability as a Function of Voltage Drop

4

% Voltage Drop

Pro

jecte

d H

ou

rs2,3

10th/90th Percentile Projections3

Average of Fleet Projections1,5

NREL cdp_fcev_89

Created: Oct-05-11 2:41 PM

1) 10% Voltage degradation is a DOE metric for assessing fuel cell performance not an indication of an OEM's end-of-life criteria.2) Projections using field data and calculated at high stack current.

3) 10th

and 90th

percentiles spans the range of stack projection. The included stacks satisfy a minimum number of operation hours and weighting factor.4) The projected hours vary based on the percentage of voltage degradation, but the projected hours do not imply that all stacks will (or do) operate to these voltage degradation levels.5) Each fleet has one voltage projection value that is the weighted average of the fleet's fuel cell stack projections.6) Only includes systems operated after 2009Q4.


CDP#90: Max Fuel Cell Stack Power

Degradation Over Operation

0

20

40

60

80

100

120

0 100 200 300 400 500 600 700 800 900 10001100120013001400150016001700180019002000

Stack Op Hour Segments2

% P

ow

er

1

Max Fuel Cell Stack3 Power Degradation Over Operation


2) Each segment point is median FC power (+-50 hrs). Box not drawn if fewer than 3 points in segment.

3) Only includes systems operated after 2009Q4.

Data Range


Group Median

Outlier

NREL cdp_fcev_90


Median power differencefrom 0 hour segment to1300 hour segment = -18.4%


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